Quality Support Group

Green Belt Exam

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Green Belt exam (SPC XL)

1. Your name (you will not get credit for your answers if you don't enter your name!)

2. A problem statement should have which of the following characteristics? (Select all that apply.)

3. A SIPOC diagram is a concise, visual way to show which of the following?

4. A well written impact statement should do which of the following? (Select all that apply.)

5. A good goal statement should include which of the following? (Select all that apply.)

6. When collecting data which of the following approaches is preferred?

7. The role of the project champion is which of the following?

8. When a DMAIC team first starts working to understand the root causes of problems, a critical first step is which of the following?

9. Useful tools for root cause problem solving include which of the following? (Select all that apply.)

10. In order to keep the DMAIC project on track, which of the following approaches are recommended? (Select all that apply.)

11. When putting together the project team, the RASCI model helps the project manager identify which of the following? (Select all that apply.)

12. In addition to managing the project plan, a DMAIC project manager should also do which of the following?

13. Using this data construct an I-MR chart. How many out-of-control conditions are represented on the Individuals chart?

14. This chart (click to view a larger image of the chart) represents the time to complete a task. A process improvement was implemented starting at point 30. What can we reasonably conclude about the new process starting from that point?

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15. The control chart below (click to view a larger image of the chart) tracks a process that had an improvement implemented at point 30. Now that the improvement appears to have been sustained for some time, what action would you recommend to make sure that you can see out-of-control conditions in the future?

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16. A plant manager is frustrated with the number of defects they’re seeing in product assemblies and they’re concerned that the number may be increasing. They want to establish a control chart to monitor this metric. Which chart is the best choice?

17. The IT department monitors all remote network connection attempts from employees. They know that time-to-connect is a critical metric and they want to establish a control chart to make sure they can see each and every out-of-control connection attempt. Which chart is the best choice?

18. A manufacturing plant has set up a new assembly cell and wants to track build times. They have a quality control engineer who can periodically sample build times. Management has established specification limits for build time and would like to track Cpk. Which chart is the best choice?

19. HR has initiated a new time-tracking system and has trained all employees on its use. They want to track the proportion of correctly submitted time sheets each week to make sure that they can see any out-of-control situations and respond to them quickly. Which chart is the best choice?

20. A process has an upper specification of 15, a mean of 13.5, and a standard deviation of 1. What is the Cp (process potential)?

21. A process has an upper specification of 15, a mean of 13.5, and a standard deviation of 1. What is the Cpk (process capability)?

22. Which of the following is not required to calculate Cpk?

23. Cp, or process potential, compares which two things?

24. A project leader is trying to help a group of customers prioritize a list of their requirements, but they can’t agree among themselves. What tool(s) could the project leader use to facilitate the discussion? (Select all that apply.)

25. DMAIC teams often identify more potential countermeasures than they can reasonably implement. Which tool is helpful in narrowing the focus to the critical few?

26. What are characteristics of a good FMEA? (Select all that apply)

27. What are characteristics of good visual management? (Select all that apply)

28. In a typical tiered management plan, where do the most frequent reviews take place?

29. A typical control plan should include which of the following? (Select all that apply.)

30. Before a DMAIC project can be closed out, which of the following must take place? (Select all that apply)

31. Which of the following can be used to track process capability for attribute/binary data? (Select all that apply.)

32. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which appraiser is struggling most with Repeatability?

33. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), what is the largest contributor to the variation?

34. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which category of measurement variation is of most concern?

35. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which results indicate the measurement system appears unacceptable? (refer to the MSA metrics slide)

36. A semiconductor company decides to test their new signal processor against a competitor's offering (the SuperX processor). They want to determine if the two processors have significantly different standard deviations. The test data for both processors is normally distributed. Use SPC XL to analyze the data (click to download the data). True or False: Using an alpha of 0.05, you can reject the null hypothesis (H0) and accept the alternative (H1) that the two processors have different standard deviations.

37. The manager of the Finance department at a small software company believes that the number of purchase orders with mistakes has increased recently. She suspects that this may be due to a new hire joining the team. To test this statistically, she pulls data from the two months prior to the new hire joining the team, and the month after. During the two months before the new hire, 30 out of 207 purchase orders were defective. During the month since the new hire joined the team, 17 out of 77 were defective.

She analyzes the data using SPC XL to determine if the proportion of defects has really changed. What should the manager conclude based on the results of the analysis?

38. A construction company sources composite wooden beams from different suppliers. They have noticed three different types of defects in the beams: cracks, chips, and holes. They use SPC XL to analyze the data (click to download the data) to see if there is a statistically significant correlation between supplier and defect type. Based on the results of the analysis, what conclusions can they draw? (Select all that apply)

39. WidgetPro, Inc. is a supply company that regularly bids on new jobs for their customer, a major manufacturer of heavy equipment. The process involves submitting multiple documents in a bid package that must meet certain criteria. Depending on the specifics of the bid, the bid packages can be approved by different people (appraisers) before submission. Recently, the manufacturer has started to reject several bid packages for non-compliance to their standard.

An attribute MSA was conducted to see if the bid appraisers were reliably able to distinguish good bid packages from bad ones. Five appraisers each reviewed 12 previously submitted bid packages two times each (half of the bid packages selected for the MSA were known to be good and half were known to be bad).

Management wants to retrain the bid appraisers. Based on your analysis of the MSA data (click to download data), who would you recommend they choose to help lead the retraining?

40. WidgetPro, Inc. is a supply company that regularly bids on new jobs for their customer, a major manufacturer of heavy equipment. The process involves submitting multiple documents in a bid package that must meet certain criteria. Depending on the specifics of the bid, the bid packages can be approved by different people (appraisers) before submission. Recently, the manufacturer has started to reject several bid packages for non-compliance to their standard.

An attribute MSA was conducted to see if the bid appraisers were reliably able to distinguish good bid packages from bad ones. Five appraisers each reviewed 12 previously submitted bid packages two times each (half of the bid packages selected for the MSA were known to be good and half were known to be bad).

Based on your analysis of the MSA data (click to download data), which statement is true?

41. An aerospace company manufactures bolts for installation on orbital rockets. The bolts have an upper limit on weight of 30 grams. An initial test run showed that the majority of the bolts exceeded the limit. A de-burring operation was added to remove burrs and other minor surface imperfections. Seventeen samples were selected and were weighed both before and after the de-burring operation and the differences calculated (click to see data).

Calculate the 99% confidence interval for the average difference. Based on your calculation, what can we say about the de-burring operation?

42. A javelin thrower wants to determine the average distance of his throws -- plus or minus 2 meters -- to establish a baseline against which he can measure future improvement. Based on some historical information, he and his coach estimate that the standard deviation of his throws is about 6 meters. How many throws should he make to estimate his average distance, plus or minus 2 meters, with 95% confidence?

43. The 8 classic wastes of Lean are (select the answers below that correctly fill in the blanks):

  1. Transportation
  2. ______________
  3. Motion
  4. ______________
  5. Waiting
  6. Over-production
  7. ______________
  8. ______________

44. The process map approach designed to highlight the responsibility for each task is which of the following?

45. Takt time shows us the pace of customer demand. Which of the following is the correct way to calculate takt time?

46. Using the House of Quality model, we are able to do which of the following?

47. The practice of removing inefficiency from a workplace by sorting materials, removing what's unnecessary, setting things in order, and sustaining that organization over time, is known as which of the following?

48. When we take samples from a larger population and plot them on a histogram, they create a child distribution. The Central Limit Theorem tells us that which property of the child distribution will be the same as that of the parent distribution?

49. When we take samples from a larger population and plot them on a histogram, they create a child distribution. The Central Limit Theorem tells us that if the sample size is sufficiently large, the child distribution will...

50. When we are comparing data sets using Hypothesis Testing, the alpha value represents how confident we need to be to reject our default hypothesis (H0) and accept the alternative (H1). If we want to be 95% confident in our conclusion, what should we set our alpha value to?

51. When considering the Cost of Poor Quality (COPQ), which of the following costs is most damaging for a company?

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